Method for catalytic conversion



Dec. 7, 1943. 'r. P. SIMPSON ET AL METHOD FOR CATALYTIC CONVERSION 2 Sheets-Sheet 2 Filed April 28, 1943 n sw m F: W 7 gm T w MN w 0 www 0 [1G m TJJ Tm Y M Y E w m. B Z) wm w m 6 5 P MA km a 4 5 M 3 Z w i i 5 k 2 F 0 67M M 9 4r Ma Mm MM; mm i p m? h m J I 4 x a a 2 F khxvfikou 8 I Z Y fl/ w kmkvswfiv 7 2 m .A 4 J 7, my M a 6 m m 4% 4 m m w p 5 A 4 CHI/PG Patented Dec. 7, 1943 METHOD FOR CATALYTIC CONVERSION Thomas P. Simpson, John W. Payne, and John A. Crowley, In, Woodbury, N. 1., assignors to Socony-Vacuum Oil Company, Incorporated, a

corporation New York Application April 28, 1943, Serial No. 484,840

3 Claims.

This invention has to do with chemical reactions which are conducted in the presence 01 a contact mass, such as, for example, the catalytic conversion of hydrocarbons.

It is known that many operations for the conversion bf hydrocarbon materials to other hydrocarbon materials of differing physical and/or chemical properties may be carried out catalytically. Most of these are carried out by contacting the hydrocarbon, usually in vapor form and at high temperature, with a contact mass composed of particles which themselves have a catalytic eflect or which are impregnated with or act as a support for other catalytic material of a nature appropriate to the result desired. Such operations may contemplate, for example, the conversion of hydrocarbons of high boiling point to those of lower boiling point, or the polymerization of light or gaseous hydrocarbons to hydrocarbons of higher boiling point. Other operations of like nature are catalytic dehydrogenation, hydrogenation, desulfurizing, partial oxidation, and similar conversions of hydrocarbon materials. The method of operation and apparatus herein described are applicable to all such conversions. 0f these operations, the vapor phase cracking of heavy hydrocarbons to gasoline is typical, and this specification will hereinafter discuss such operation as exemplary, without, however, intending to be limited thereby or thereto except by such limits as may appear in the claims.

Such catalytic processes generally make use of reaction chambers containing a fixed body of catalyst or contact mass through which the reaction mixture is passed and in which, after the reaction has slowed down to an uneconomic point, the contact mass is regenerated in situ. Such processes are not continuous and only attain continuity by the provision of numerous reaction chambers which are alternately placed on stream and on regeneration. Likewise, it is difilcult to maintain constant quantity and quality of product without'numerous chambers and intricate scheduling because of the progressively decreasing activity of catalyst. This same feature, with apparatus limitations, prevents, to a degree, the use of catalyst at a uniform-high efficiency level. Most of these difllculties may be avoided by the use of a method wherein the catalyst or contact mass is handled continuously as well. This invention is specifically directed to such a process.

This invention has for its object the provision of a process of hydrocarbon oil conversion wherein a continuously moving stream of hydrocarbon oil, preferably in the form of vapor heated to conversion temperature, is contacted with a continuously moving stream of catalyst for the ac-- complishment of conversion. Important advantages of the process contemplated herein are that the catalytic material is used only at a high level of efilciency and that it is continuously regenerated and returned to the conversion step, both operations being conducted under controlled conditions. The said high level of catalyst efliciency and constant uniformity in the character of the regenerated catalyst are obtained primarily by controlling the conditions in the regenerating zone so that the temperature of the catalyst (from which, in the case of hydrocarbon conversion, carbonaceous deposits must be oxidized or burned) is maintained within the temperature range for efficient regeneration and at the same time is not permitted to rise above the maximum combustion temperature which would cause substantial heat damage to the catalyst particles.

This temperature control in the regenerator is accomplished by effecting a positive thermal exchange between the moving catalyst mass and a heat exchange medium maintained within the moving mass or body of catalyst in indirect heat transfer relation therewith. In the regeneration of catalyst in a hydrocarbon conversion or continuous catalytic cracking operation, heat is posi tively extracted from within the moving mass of catalyst in the regenerating zone so that the temperature in such zone is not permitted to rise to a point where the catalyst particles would be damaged and at the same time the rate of withdrawing such heat is such that an efflcient re-' generating or. combustion temperature is maintained. As willhereinafter appear, this positive withdrawal of heat is effected by a plurality of heat transfer tubes extending into the mass of catalyst moving through the zone or chamber in which it is regenerated. These tubes may be either parallel with or transverse to the direction of catalyst flow.

In order that this invention may be understood, reference is made to the drawings attached to and made a part of this specification. In these drawings, Figure 1 shows in diagram form a reaction and regeneration apparatus suitable for use in this process. Figures 2, 3, 4, 5, and 6 are concerned with internal details of such chambers, Figure 7 shows in diagram form a set-up of apparatus suitable for the conversion of hydrocarbon oils, and Figure 8 shows an optional form of a portion of the apparatus.

In Figure 1, character 8 denotes a regeneration chamber: 9 a purging section; N a reaction chamber; II a second purging section; and I2 an elevator for catalyst particles. Regeneration chamber 8 and reaction chamber III are similar in construction and internal fittings and consist (referring now to 8) of an exterior shell 8, which may be cylindrical or rectangular in cross-section, with a convergent sealed top I 3 and a. convergent bottom 14 and fitted with an interior false bottom l5, which is perforate, the perforations therein being too small for the passage of catalyst particles but permitting the passage of liquid or gas. Bottom [4 is fitted with pipe l8, and top l3 with pipe ll. At the top of I3 is a sealed feeding device I8, which may be a star wheel as shown, an intermittently-operated valve set-up, or other common device of this nature. Catalyst material introduced through l8 fills the interior of shell 8, passes down therethrough, is collected by false bottom l and chute l9 and is removed by a second intermittently-operating device, such as star wheel 20. This arrangement eifects a continuously moving stream of catalytic material through shell 8.

Reaction mixture--in this case, air for an oxidizing regeneration-may be introduced through pipe l8, and products of reaction-4n this case, fiue gasmay be removed through pipe ll. This efiects a continuously-flowing stream of reaction material in physical contact with the continuously-flowing stream of catalytic material in shell 8. The flow shown is '"countercurrent. If desired, it may be made concurrent by reversing the functions of it and El. Shell 8 is also internally fitted with a series of conduits 2i equipped with fins 22 joined to headers 23 and 2 3 through which a heat exchange medium may be passed by means of pipes 25 and 2B. The heat exchange medium may be used to control the temperature of reaction by extraction of heat from or addition of heat to the material within shell 8, and its flow may be concurrent, countercurrent, or, as later shown, transverse to the direction of flow of catalytic material. Thus, in the regenerator d the temperature of the mass of catalyst under regenerator is closely controlled by eifecting a positive exchange of heat between the catalyst and the heat transfer medium maintained within the body of catalyst and in indirect heat exchange relation therewith throughout the conduit system illustrated in Figures 1 and 2 as comprising tubes 2i. Shell ill is similarly fitted and similarly operated.

Reaction material, in this case hydrocarbons, is introduced by El and removed by 28; catalyst movement is controlled by 23 and 38; and heat exchange medium is circulated by pipes 3i and 32. Confined passage 9, maintained relatively full of catalyst by devices 20 and 29, is fitted with pipes 33 and 34, bymeans of which steam may be passed through theg atalyst for purging, thereby preventing the passage of regenerating agent into the conversion chamber. Thus, section 9 provides a substantially gas-tight seal between the two chambers. A similar purging passage ll connects with the bottom portion of shell l0 and is shown as being controlled by devices 30 and 35. The leg or passage H is fitted with steam connections 36 and 31 for purging the catalyst after the reaction or conversion step so as to prevent hydrocarbons other than deposited on the spent catalyst being conducted from the bottom of the conversion chamber In into regenerating chamber 3. From II the catalyst drops through 35 into boot 38 or elevator l2, by which it is elevated and discharged into bin 38a above shell 8. Elevator l2 may be of the belt and bucket type shown or of any other kind suitable for the physical properties of the catalytic materials.

It will be apparent from the foregoing that the apparatus shown in Figure 1, wherein there is a controlled gravity flow of catalyst through shells or chambers 8 and to into the feed boot 38 of the elevator I2, which returns the spent catalyst to the inlet of shell I0, provides means for carrying out the continuous catalytic process contemplated herein with high thermal efficiency because there is a general continuous movement of catalyst through the system substantially directly from one chamber to the other and the hot catalyst does not have an opportunity to cool to atmospheric temperature during its movement through the circuit. Obviously, arrangements other than that described above may be employed to effect the movement of catalyst substantially directly from each zone to the other without permitting it to cool to atmospheric temperature.

Customary devices for the removal of fines and the addition of makeup may be inserted in the catalyst conveyor system.

Special attention should be given to the arrangement of heat exchange tubes within the shells 8 and iii. These should be arranged so as to permit the passage of catalytic material and reaction material longitudinally through. the shell in such manner that flowing material is brought into the desired heat exchange relationship with heat exchange medium. The conduits may be unfinned, but better results are obtained if the external heat transfer surface of the heat exchange tubes is augmented by the addition of fins thereto. These fins, primarily added for. heat transfer reasons, may be taken advantage of to assist in control of the fiow of catalyst and reaction fluid and contact therebetween by being disposed so that they, together with the tubes, divide the space within the shell into a series of longitudinal passages of substantially constant cross-section throughout their length. The arrangement of these passages should be such that the reaction material or catalyst moving through the shell comes in eflicient heat exchange relationship with the heat exchange medium in the tubes. The proper dimensions for this condition depend somewhat upon the physical nature of the catalyst. A commonlyused catalyst for such purposes is a rod-shaped clay particle about 2 /2 mm. diameter by 4 mm.

average length, and with such particles it is desirable that the passages be so arranged that no catalyst particle will be further removed from a heat extractive surface than about 1 inch, and the total volume in cubic inches of the passages containing catalyst and reaction mixture should be numerically about one-eighth to twice the surface in square inches of the heat transfer surface in contact with the passages. Catalyst particles of different heat-conductivity or of different packing characteristics, or variations in the contemplated intensity of reaction per unit volume of catalyst, as well as considerations of heat transfer and pressure drop will vary the ratio somewhat. The length of the paths 4 through which the catalyst moves during reac- Figure 2 shows a cross-section of case 8 at the level 2-2 showing how the preferred longitudinal passages may be formed by equipping each heat exchange tube with two diametrically-opposed, longitudinally-disposed axial fins. Figures 3 and 4 show other ways of arriving at the same result. The heat transfer tubes need not be arranged parallel to the flow of catalyst but may well be transverse thereto, as shown in Figures 5 and 6, wherein transverse tubes 39, carrying fins 40, extend between header boxes 4| and 42 in a shell 43, to exercise the same functions as corresponding parts in shells 8 and I8; and, as aforesaid, the spacing and arrangement of the heat exchange tubes or conduits may be varied depending upon the character of the catalystand the intensity of the reaction in the chamber-or zone.

The heat exchange medium may be any fluid suitable for the load and temperature levels encountered, such as gases, liquids of various kinds,

molten metals, or alloys, or fused salts. Preferably, it should be possessed of a low vapor pressure, low viscosity, and high specific heat at temperatures between 600 and 1100 F., non-corrosive to steel, and fluid at about 300-35o F, so that it may be removed from shut-down apparatus by steam heating- Convenient materials for such use are mixtures of the strong alkali salts of the oxy-acids of nitrogen.

Passages 9 and I I, used for purging by passing steam through the catalyst particles, should be so proportioned that a sufllcient contact of steam and catalyst particles occurs to remove most of the residual products of the preceding reaction.

Reference is now made to Figure 7, which shows an operating set-up appropriate for a conversion of hydrocarbons, such as the vapor phase cracking of petroleum hydrocarbons to form gasoline. A charge oil or charging stock of the type conventionally used in'cracking operations is fed through pipe 44 by pump 45 to a vapor preparation unit 48. Vapor preparation unit 45 will consist essentially of a heater, for which purpose any of the usual forms of heater common in the art-say, a pipe stillmay be used, to heat and vaporize the charge and heat it to reaction temperature, and, if the charge used is not wholly vaporized at the reaction temperature, of a vapor separator to remove unvaporized liquid residue. 41 into and through reaction chamber 48 (the same as l0, Figure 1), and therein they undergo catalytic reaction. Reaction product pass through pipe 49 to product purification and recovery equipment denoted by 50. The equipment 50 may be made up 01' any of the usual fractionation, separation, and disposal devices currently in common use for handling products of cracking reactions. If desired, product fractions boiling above the desired low-boiling'product may be returned to the system for re-treatment, either separately or in admixture with fresh charge. Catalytic material flowing from 48 is purged in 5| and is elevated by 52, which introduces spent catalyst into the top of chamber 53. In chamber 53 the spent catalyst moving downwardly there- I through is regenerated by burning with air supplied by blower and pipe 54, the products of regeneration being disposed of through pipe 55. The regenerated catalyst is purged in 55 and returned to 48. The temperature level of the reaction in 48 may be controlled and latent heat of reaction added thereto by a heat exchange Vapors from 48 move through pipe medium introduced through pipe 51 and removed through pipe 58. The same heat exchange medi- .um may, in the arrangement shown in Figure 7.

. be used to control the temperature of regener- 5 ation in 53. As aforesaid, the heat exchange medium in the regenerating or reviviflcation zone 53 is used to control the temperature of regeneration by positively removing heat from within the body of moving catalyst therein in a manner and at. a rate such that the temperature of the catalyst does not drop below the temperature for efficient regeneration or combustion and does not rise above the. temperature which would cause substantial heat damage to the catalyst material. For example, the temperature for regeneration of a spent clay catalyst for cracking hydrocarbons may range from around the cracking temperature (from about 800 F. to about950 F.) to a. peak temperature in the neighborhood of go 1050 F. to 1100 F. Care should be exercised in the control of the temperature of the heat exchange medium circulated in the regenerator so that the temperature of the catalyst passing through the regenerator does not rise substantially above 1200" F., or serious damage to a catalyst of this type may result. In the arrangement shown in Figure 7 the heat exchange medium is introduced into heat exchange conduits in regenerator 53 by pipe 59 and is removed by pipe 60. It is circulated by pump ii. The temperature for the several uses may be controlled by use of various combinations of heat'exchangers 52 and 55 and by-passes 64, 85, and 85 in a manner obvious to those skilled in the art.

In many cases, if the reactions taking place in chamber 48 have a relativelysmall heat of reaction or where maintenance of closelyv controlled temperatures is not essential it is unnecessary to I circulate the heat transfer medium through reaction chamber 48, and a satisfactory heat balance and temperature level can be attained by balancing the temperatures of the entering reactants and catalyst. Many of the usually practiced conversions of petroleum fractions are of such nature. Where the equipment is installed exclusively or principally for such conversions, it is usual to omit the heat transfer structures, in the reactor, using a substantially open-bed reactor as shown in Figure 8, which is self-explanatory. i

As an example of one operation successfully conducted in such apparatus according to the process herein disclosed, coastal gas oil with 10 oil 1 water (cold volumes) at a temperature of 800 F. was contacted with a catalyst of activated clay gran- 30 ules at a rate of one volume of oil (cold) to four Yield of 410 E. P. gasoline (including isobutane and heavier in gas) volume per cent 67.4 Yield of drygas (lighter than isobutane 7o weight per cent- 4.0 Yield of coke do 2.5 Yield of recycle stock volume per cent" 35.0

In this run the catalyst was passed through I the regeneration chamber (of the same size as the reaction chamber) at the same rate and was which was admixed steam to the extent of about burned with a sufficient volume of air to maintain above per cent CO: in the exit flue gas.

The temperature of the reaction was held by use of the heat exchange medium at 800' 1"., and in the same manner the temperature of the regeneration was not allowed to rise above 1100' F.-

The gasoline produced was of excellent quality, high in anti-knock rating, and the recycle stock was clean, light in color, and of about the same boiling point as the charge. No high-boiling, dirty, liquid cracking tar was produced. The regenerated catalyst was equal in efliciency to new catalyst, no detectable deterioration in quality being found.

It is noted that hereinbefore-we have stated that the length of the paths in which contact is effected between catalyst and reactant should be relatively great, say from 3 to feet or more. This is based upon the discovery that, other things being equal, increases in the length of path which the reactant follows through the contact mass increase the value of the results ob tained. This is shown by the data in the following table.

(a) Space velocity is expressed as volumes of oil, measured as a liquid at 60 F. passed through 1 unit volume of catalyst in 1 hour.

(b) Pressure, p. s. i., gauge, at exit from catalyst.

It will be noted from the above table that substantial increases of yield are experienced with increases of length of path of reactant through catalyst. These were not due to mere exposure of reactant to more catalyst, since the space velocity which expresses that degree of exposure was substantially the same in all instances.

While the exact length of path utilized will vary with various charging stocks and in view of various objects to be accomplished, it will generally be desirable to utilize a path of reactant passage through the catalyst having a minimum length of at least about 3 feet, up to at least about 15 feet or more. It will be desirable to utilize for practically all operations a minimum path length of at least about three feet. It is preferable for most commercial cracking operations, to use a minimum 'path length of at least about five feet. The useful length of path for certain types of operations, such as reforming of naphthas, etc., preferably will be not less than about fifteen feet and in any form of hydrocarbon conversion path lengths ranging at least up to about 40 feet will be found useful.

It is to be understood that the specific examples and numerical data herein disclosed are set forth only as exemplary and that the invention is not to be limited thereby or thereto but it is to be subject only to those limitations expressed in the following claims.

The subject matter of this application has been continuously Pending before the United States Patent Oflice since September 4, 1937, the filing date of our application, Serial No. 162,541, the continuity having been effected through the medium of our application, Serial No. 361,440, filed October 16, 1940, of which this application is a continuation-in-part. Therefore, this application is a continuation-in-part of application, Serial No. 162,541.

We claim:

l. A continuous cyclic method for the catalytic conversion of fluid petroleum hydrocarbons into high-quality gasoline, which comprises: moving a mass of active catalyst particles through a con version zone; passing fluid petroleum hydrocarbons through said conversion zone under high temperature conversion conditions in contact with said moving catalyst mass through a path such that the hydrocarbon must pass through a minimum depth of catalyst of at least about three feet, whereby the said conversion is effected and the catalyst particles become spent by deposition of carbonaceous material; passing the spent cata lyst particles as a moving mass from said conversion zone into and through a regenerating zone; j'

contacting the spent catalyst particles with an oxidizing gas in said regenerating zone, thereby burning off the said carbonaceous deposit with generation of heat; positively withdrawing heat of combustion from within the moving catalyst mass at a rate such that the temperature is not permitted to rise to a point which would cause substantial heat damage to catalyst particles and returning regenerated catalyst to said conversion zone, said heat withdrawal being effected with a heat transfer medium in indirect heat exchange relation with catalyst particles.

2. A continuous cyclic method for the catalytic conversion of fluid petroleum hydrocarbons into high-quality gasoline, which comprises: moving a mass of active catalyst particles through a conby burning of! the said carbonaceous deposit with the'generation of heat; positively withdrawing heat of combustion from within the moving catalyst mass with a temperature-controlled fluid heat exchange medium maintained in indirect heat transfer relation therewith so as to prevent substantial heat damage to the catalyst particles; returning the regenerated catalyst to said conversion zone; and substantially excluding oxidizing gases from entering the conversion zone.

3. The method of converting a petroleum hydrocarbon oil into high-quality gasoline by a process comprising catalytic cracking, which method comprises: heating the oil to form vapors at conversion temperature; introducing the heated vapors into a substantially-compact, moving mass of catalyst in a conversion zone, to pass through said catalyst in a path having a minimum depth of at least about three feet, whereby said vapors are converted and carbonaceous material is deposited on saidcatalyst; introducing catalyst into said conversion zone and removing catalyst from said conversion zone without'appreciable losses of hydrocarbon vapors with said catalyst; continuously regenerating said removed catalyst by moving it as a substantially compact mass through a regenerating zone; passing combustion-supporting gas through the catalyst in the regenerating zone to burn 0115 the carbonaceous deposit with the generation of heat; positively withdrawing part of the heat of combustion from within the moving mass of catalyst with an indirectly contacted heat transfer medium at such a rate as to prevent the establishment of temperature conditions which would cause substantial heat damage to the catalyst particles and at the same time the said rate or heat withdrawal being such that an efllclent regeneration temperature ismaintained within the moving mass of catalyst; substantially directly returning the high temperature regenerated catalyst to said conversion zone; preventing any substantial amount of combustion-supporting regeneration gases from entering the conversion zone from said regenerating zone; and fractionating the products from the conversion step.

THOMAS P. SIMPSON.

JOHN W. PAYNE.

JOHN A. CROWLEY, J R. 

